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RETURN TO MAIN MENU
IM10040
February, 2011
POWER WAVE
C300
11672
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation ...
and thoughtful operation on your
part.
DO
NOT
INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT
WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
OPERATOR'S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric POWER WAVE IM10040
Summary of Contents for Lincoln Electric POWER WAVE IM10040
- Page 1 RETURN TO MAIN MENU IM10040 February, 2011 POWER WAVE C300 11672 For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
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Page 2: California Proposition 65 Warnings
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. bE SuRE ThAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDuRES ARE PERFORMED ONLY bY QuALIFIED INDIVIDuALS. -
Page 3: Electric Shock Can Kill
ELECTRIC ShOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING and CuTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAuTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 SAFETY Electromagnetic Compatibility (EMC) Conformance Introduction Installation and Use Assessment of Area...
- Page 7 SAFETY Electromagnetic Compatibility (EMC) Methods of Reducing Emissions Mains Supply Maintenance of the Welding Equipment Welding Cables Equipotential Bonding Earthing of the Workpiece Screening and Shielding...
- Page 8 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 9: Table Of Contents
viii Installation...Section A Technical Specifications ...A-1, A-2 Safety Precautions ...A-3 Location, Lifting ...A-3 Stacking ...A-3 Tilting...A-3 Input and Ground Connections ...A-3 Machine Grounding ...A-3 High Frequency Protection...A-3 Input Connection ...A-4 Input Fuse and Supply Wire ...A-4 Input Voltage Selection ...A-4 Power Cord Replacement ...A-4 Connection Diagram ...A-5 Recommended Work Cable Sizes ...A-5... -
Page 10: Table Of Contents
Maintenance ...Section D Safety Precautions ...D-1 Routine Maintenance ...D-1 Periodic Maintenance...D-1 Calibration Specification...D-1 ________________________________________________________________________________ Troubleshooting ...Section E Safety Precautions...E-1 How to Use Troubleshooting Guide...E-1 Using Status LED and Error Fault Codes ...E-2, E-4 Troubleshooting Guide...E-2 thru E-5 Error Fault Codes ...E-6, E-7 ________________________________________________________________________________ Wiring Diagram and Dimension Print ...Section F ________________________________________________________________________... -
Page 11: Installation
TEChNICAL SPECIFICATIONS - POWER WAVE® C300 POWER SOuRCE-INPuT VOLTAGE AND CuRRENT Input Voltage ± 10% Model Duty Cycle 40% rating 208/230/400*/460/575 K2675-2 100% rating (* includes 380V to 415V) Process Duty Cycle Volts (RMS) at Rated Amperes GMAW GMAW-Pulse FCAW 100% SMAW 100%... -
Page 12: Physical Dimensions
WIRE FEED SPEED RANGE-WIRE SIzE WFS RANGE 50 – 700 ipm (1.3 – 17.8 m/min) PROCESS GMAW GMAW-Pulse FCAW GTAW-DC SMAW Wire Speed MODEL hEIGhT K2675-2 18.8in (478mm) OPERATING TEMPERATuRE RANGE Environmentally Hardened: -4°F to 104°F (-20C to 40C) IP23 155º(F) Insulation Class Weight does not include input cord. -
Page 13: Safety Precautions
National Electrical Code, all local codes and the information in this manual. MAchINE GROUNDING The frame of the welder must be grounded. A ground ter- minal marked with a ground symbol is located next to the input power connection block. -
Page 14: Input Connection
Using input wire sizes, fuses or cir- cuit breakers smaller than recommended may result in "nuisance" shut-offs from welder inrush currents, even if the machine is not being used at high currents. INPuT VOLTAGE SELECTION The POWER WAVE®... -
Page 15: Recommended Work Cable Sizes
RECOMMENDED WORK CAbLE SIzES FOR ARC WELDING A 15 ft. work cable is provided with the POWER WAVE® C300. This cable is appropriately sized for all of the POWER WAVE® C300’s welding procedures. If the work cable needs to be replaced a similar quality of cable should be used as excessive voltage drops caused by undersized welding cables can result in unsatisfactory welding performance. -
Page 16: Cable Connections
CAbLE CONNECTIONS There are two circulars connector in the wire drive compart- ment. (See 4-pin and 12-pin---Figure A.2---Table A.1) FIGuRE A.2 CAbLE INDuCTANCE AND ITS EFFECTS ON WELDING Whenever possible always weld in a direction away from the work (ground) connection. Excessive cable inductance will cause the welding performance to degrade. -
Page 17: Shielding Gas Connections
• Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other live electrical circuits. -
Page 18: Loading Spools Of Wire
LOADING SPOOLS OF WIRE WARNING • Keep hands, hair, clothing and tools away from rotating equipment. • Do not wear gloves when threading wire or changing wire spool. • Only qualified personnel should install, use or service this equipment. ------------------------------------------------------------------------ Loading 10 to 15 lb. -
Page 19: Wire Drive Configuration
WIRE DRIVE CONFIGuRATION (See Figure A.4) Changing the Gun Receiver bushing WARNING ELECTRIC ShOCK can kill. • Turn the input power OFF at the welding power source before instal- lation or changing drive rolls and/or guides. • Do not touch electrically live parts. •... -
Page 20: Gun Used
INSTALLATION 1. Press end of gun against a solid object that is elec- trically isolated from the welder output and press the gun trigger for several seconds. 2. If the wire "birdnests", jams, or breaks at the drive roll, the drive roll pressure is too great. -
Page 21: Tig Welding
A-11 TIG WELDING (Figure A.7) Tig uses Electrode Negative Polarity so for this appli- cation, connect the Tig torch to the negative (-) output stud and connect the work clamp to the positive (+) output stud. The TIG torch gas connection should be connected to the POWER WAVE®... -
Page 22: Operation
SAFETY PRECAuTIONS READ AND uNDERSTAND ENTIRE SECTION bEFORE OPERATING MAChINE. WARNING • ELECTRIC ShOCK CAN KILL. unless using COLD FEED fea- ture, when feeding with gun trig- ger, the electrode and drive mechanism are always electri- cally energized and could remain energized several sec- onds after the welding ceases. -
Page 23: Product Description
PRODuCT DESCRIPTION The Power Wave® C300 is a high performance multi- process machine with GMAW, FCAW, SMAW, DC TIG, and pulse capability. It will offer a premier weld- ing performance solution for specific areas such as aluminum, stainless, nickel where size and weight are an issue. -
Page 24: Design Features
DESIGN FEATuRES Loaded with Standard Features • Multiple process DC output range: 5 - 300 Amps. • 200 – 600 VAC, 1/3 phase, 50-60Hz input power. • New and Improved Line Voltage Compensation holds the output constant over wide input voltage fluctuations. -
Page 25: Case Front Controls
CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure b.1) 1. LEFT DISPLAY- Shows wire feed speed or amper- age, 2. LEFT KNOb- Adjusts value in left display. 3. MAIN DISPLAY- Shows detailed welding and diag- nostic information. -
Page 26: Case Back Controls
CASE bACK CONTROLS 1. EThERNET CONNECTOR 2. POWER CORD 3. GAS CONNECTION, GMAW AND FCAW 4. Gas Connection, GTAW OPERATION FIGuRE b.2 POWER WAVE® C300... -
Page 27: Internal Controls
INTERNAL CONTROLS (Code 11479) 1. SPINDLE bRAKE 2. WIRE DRIVE PRESSuRE ARM 3. ThuMb SCREW, FOR SECuRING ThE WELDING GuN 4. GuN buShING 5. SOCKET hEAD CAP SCREW FOR SECuRING ThE GuN buShING 6. GAS CONNECTION, GMAW OR FCAW GuN OPERATION FIGuRE b.3 7. -
Page 28: Making A Weld With Waveform Technology Power Sources
The serviceability of a product or structure utiliz- ing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are... - Page 29 A M P S U l t i m A r c ™ C o n t r o l W E L D M O D E E N D O P T I O N S A M P S O F F S T A R T O P T I O N S S E T U P...
- Page 30 SMAW (STICK) WELDING SMAW is most often used for outdoor construction, pipe welding and general repairs. The wire feeder controls Amperage, Output Control and Arc Force dur- ing SMAW welding. During SMAW welding the wire drive remains idle. AMPS CC STICK MODES PROCESS Stick Soft(7018) Stick Crisp(6010)
- Page 31 b-10 NON-SYNERGIC GMAW AND FCAW WELDING In non-synergic modes, the WFS control is similar to a conventional CV power source where WFS and volt- age are independent adjustments. Therefore to main- tain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.
- Page 32 b-11 GMAW (MIG) SYNERGIC WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine. The nominal pre- programmed voltage is the best average voltage for a given wire feed speed, but may be adjusted to prefer- ence.
- Page 33 b-12 STEEL AND STAINLESS SYNERGIC GMAW-P (PuLSED MIG) WELDING When pulse welding, the power source primarily regu- lates the arc current, not the arc voltage. During a pulsing cycle, arc current is regulated from a low background level to a high peak level and then back down to the low background level.
- Page 34 w i t h a s t i f f a r c . A d j u s t s t h e t i m e t h a t s h i e l d i n g P o s t f l o w T i m e w i r e f o r t h e n e x t a r c s t a r t .
- Page 35 b-14 ALuMINuM SYNERGIC GMAW-P (PuLSED MIG)AND GMAW-PP (PuLSE ON PuLSE) WELDING The Power Wave® C300 can produce top quality alu- minum welds with excellent appearance, little spatter and good bead shape. Push-pull guns are available for consistent feeding when welding a long distance away from the wire feeder.
- Page 36 b-15 ALuMINuM GMAW-P (PuLSED MIG) t r o l o v e r t h e p u d d l e a n d h i g h F o r P u l s e m o d e s , A r c C o n t r o l w e l d .
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Page 37: Weld Mode Searching
b-16 GTAW (TIG) WELDING The Power Wave® C300 is excellent for Touch Start TIG welding. AMPS WELD MODE MODE TOUCH START WELD MODE UltimArc™ Control UltimArc™ Control No UltimArc™ Control are active for Touch Start TIG. WELD MODE SEARChING The Weld Mode Search feature allows the selection of a welding mode based on certain criteria (wire size, process type, etc.). -
Page 38: Procedure/Memory Panel Operation
b-17 DuAL PROCEDuRE/MEMORY PANEL OPERATION The Dual Procedure/Memory Panel performs three functions: • Weld procedure selection • Memory save and recall • Limits setting There are two procedure memories (A and b) and eight user memories (1-8). Procedure Memory vs. user Memory Procedure memory is used while welding. - Page 39 LIMITS Limits allow the welder to adjust the welding proce- dure only within a defined range. Each user memory may have a different set of limits. For example, memory 1 can be set to limit the WFS to 200 through 300 in/min, and memory 2 can be set to limit the WFS to 275 through 310 in/min, while memo- ry 3 may not have any WFS limits.
- Page 40 b-19 If the passcode does not equal zero (0000), enter the passcode now. If the passcode has been forgotten, a p.c. computer application or Palm O.S. application is required to change the passcode. Memory Value high Limit HI = 200 LO = 180 WELD WFS WELD MODE...
- Page 41 4-Step Trigger 4-Step trigger operation gives the welder additional control in the welding sequence. 4-Step trigger allows the welder to choose the arc start, weld and arc end time. It may also be set-up to work as a trigger inter- lock.
- Page 42 b-21 ExAMPLE 1 - 2 STEP TRIGGER: Simple operation The simplest trigger operation occurs with a 2 Step trigger and the Start, Crater and Burnback functions all set to OFF. (See Figure B.11) For this sequence, PREFLOW: Shielding gas begins to flow immediately when the gun trigger is pulled.
- Page 43 b-22 ExAMPLE 2 - 2 STEP TRIGGER: Improved Arc Start and Arc End. Tailoring the arc start and arc end is a common method for reducing spatter and improving weld quality. This can be accomplished with the Start and Burnback functions set to a desired values and Crater set to OFF.
- Page 44 b-23 ExAMPLE 3 - 2 STEP TRIGGER: Customized Arc Start, Crater and Arc End. Sometimes it is advanta- geous to set specific arc start, crater and arc ending parameters for the ideal weld. Many times when welding aluminum crater control is necessary to make a good weld.
- Page 45 ExAMPLE 4 – 4 STEP TRIGGER: Trigger Interlock The 4 step trigger can be configured as a trigger inter- lock. Trigger interlock adds to the welder’s comfort when making long welds by allowing the trigger to be released after an initial trigger pull. Welding stops when the trigger is pulled a second time and then released, or if the arc is interrupted.
- Page 46 Start and less heat desired during crater. With 4 step trigger, the welder chooses the amount of time to weld at the Start, Weld and Crater settings by using the gun trigger. Burnback...
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Page 47: Cold Feed/Gas Purge Switch
b-26 COLD FEED/GAS PuRGE SWITCh Cold Feed and Gas Purge are com- bined into a single spring centered tog- gle switch. To activate Cold Feeding, hold the switch in the FORWARD position. The wire drive will feed electrode but neither the power source nor the gas solenoid will be energized. - Page 48 b-27 • The Power Wave® C300 is now configured and ready to weld in the synergic mode. • Adjustment of the SPD value from the set value has the affect of adjusting trim or arc length. • To increase the arc length; increase the SPD value at the Power Wave®...
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Page 49: Set-Up Feature Menu
b-28 The Setup Menu gives access to the Setup Configuration. Stored in the setup configuration are user parameters that generally only need to be set at installation. The parameters are grouped as shown in the following table. PARAMETER P.1 through P.99 P.101 through P.199 P.501 through P.599 SET-uP FEATuRES MENu... - Page 50 b-29 Parameter Exit Setup Menu This option is used to exit the setup menu. When P.0 is displayed, press the Left Button to exit the setup menu. Wire Feed Speed units This option selects which units to use for displaying wire feed speed. English = inches/minute wire feed speed units (default).
- Page 51 b-30 Parameter Procedure Change Method Selects how remote procedure selection (A/B) will be made. The selected procedure can be changed locally at the user interface by pressing the 'A-Gun-B' button. The following methods can be used to remotely change the selected procedure: •...
- Page 52 b-31 Parameter Gun Offset Adjustment This option adjusts the wire feed speed calibration of the pull motor of a push-pull gun. This should only be performed when other possible corrections do not solve any push-pull feeding problems. An rpm meter is required to perform the pull gun motor offset calibration. To perform the calibration procedure do the following: 1.
- Page 53 All Mode Remote = This setting allows the remote control to function in all weld modes which is how most machines with 6-pin and 7-pin remote control connections operate. This setting was provided so that customers with a mix of Lincoln Electric equipment can have consistent remote control behavior across all of their equipment. (N. American default) Joystick MIG Gun = Use this setting while MIG welding with a push MIG gun with a joystick control.
- Page 54 b-33 Parameter P.22 Arc Start/Loss Error Time This option can be used to optionally shut off output if an arc is not established, or is lost for a specified amount of time. Error 269 will be displayed if the machine times out. If the value is set to OFF, machine output will not be turned off if an arc is not established nor will output be turned off if an arc is lost.
- Page 55 b-34 Parameter P.102 View Fatal Logs Used for viewing all the system fatal logs. Press the Right Button to enter the option. Rotate Control Knob to select the desired fatal log to read. Press the Right Button again to enter that log.
- Page 56 b-35 Parameter P.503 Memory button Disable Disables the specified memory button(s). When a memory is disabled, welding procedures can- not be restored from or saved to that memory. If an attempt is made to save or restore a dis- abled memory, a message will be displayed on the lower display indicating the memory number is disabled.
- Page 57 b-36 Parameter P.507 uI Clear All Memories Allows the operator to quickly set all memories to the default weld mode and welding parame- ters. Presently, this option does not exist in any setup menu. P.509 uI Master Lockout Locks all user interface controls, preventing the operator from making any changes. This para- meter can only be accessed using Power Wave Manager.
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Page 58: Accessories
Requires K2909-1, 6-pin to 12-pin adapter. Portable current control provides the same dial range as the current control on the welder. Consists of a 6-pin Amphenol connector which plugs into the remote control Amphenol. 25 foot cable length. TIG OPTIONS... -
Page 59: Wire Feed Options
WIRE FEEDER OPTIONS K2447-1 PYThON-PLuS PuSh-PuLL GuN Air-Cooled, 15 ft.(4.5m). Requires K2910-1, 7-pin to 12-pin adapter. K2447-2 PYThON-PLuS PuSh-PuLL GuN Air-Cooled, 25 ft.(7.6m). Requires K2910-1, 7-pin to 12-pin adapter. K2447-3 PYThON-PLuS PuSh-PuLL GuN Air-Cooled, 50 ft.(15.2m). Requires K2910-1, 7-pin to 12-pin adapter. -
Page 60: Routine Maintenance
SAFETY PRECAuTIONS ELECTRIC ShOCK can kill. • Turn the input power to the welding power • Only qualified personnel should install, use or ------------------------------------------------------------------------ ROuTINE MAINTENANCE Routine maintenance consists of periodically blowing out the machine, using a low-pressure air stream, to remove accumulated dust and dirt from the intake and outlet louvers, and the cooling channels in the machine. -
Page 61: How To Use Troubleshooting Guide
TO uSE TROubLEShOOTING GuIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 62 uSING ThE STATuS LED TO TROubLEShOOT SYSTEM PRObLEMS Not all of the Power Wave C300 errors will be displayed on the user interface. There are three status lights that contain error sequences that may not show up on the user interface. If a problem occurs it is important to note the condition of the status lights.
- Page 63 Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR ThE POWER WAVE® The following is a partial list of possible error codes for the POWER WAVE® C300. For a complete listing consult the Service Manual for this machine. MAIN cONtROL BOARD ( “StAtUS”...
- Page 64 Observe all Safety Guidelines detailed throughout this manual Error Code # Peak input current limit Under-voltage lockout Thermal Fault Pre-charge timeout Transformer primary over current Other If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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Page 65: Troubleshooting
2. Reduce output current, duty cycle, or both. 3. Contact your local authorized Lincoln Electric Field Service facility for technical assistance. 1. Make sure input supply discon- nect has been turned ON. Check input fuses. Make certain that the Power Switch (SW1) on the power source is in the “ON”... - Page 66 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Thermal LED is ON Thermal LED is ON “Real Time Clock” no longer func- tioning General degradation of weld perfor- mance If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 67 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Weld and Arc Quality Problems (Continued) Wire burns back to tip at the end of the weld. Machine output shuts down during a weld. Machine won’t produce full output. Excessively long and erratic arc. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 68 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Cannot Connect Connection Drops while welding If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TROubLEShOOTING POSSIbLE CAuSE...
- Page 69 DIAGRAMS Enhanced Diagram POWER WAVE® C300...
- Page 70 DIMENSION PRINT 1 8 . 8 0 6 . 9 3 1 3 . 9 4 2 4 . 0 4 2 7 . 4 3 27.43 18.80 6.93 13.94 24.04 POWER WAVE® C300...
- Page 71 NOTES POWER WAVE® C300...
- Page 72 NOTES POWER WAVE® C300...
- Page 73 WARNING Spanish AVISO DE PRECAuCION French ATTENTION German WARNuNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
- Page 74 Spanish PRECAuCION French ATTENTION German WARNuNG Portuguese Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 75 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...